Apparatus for combusting a fuel at high pressure and high temperature, and associated system

ABSTRACT

A combustor apparatus is provided, comprising a mixing arrangement for mixing a carbonaceous fuel with enriched oxygen and a working fluid to form a fuel mixture. A combustion chamber is at least partially defined by a porous perimetric transpiration member, at least partially surrounded by a pressure containment member. The combustion chamber has longitudinally spaced apart inlet and outlet portions. The fuel mixture is received by the inlet portion for combustion within the combustion chamber at a combustion temperature to form a combustion product. The combustion chamber directs the combustion product longitudinally toward the outlet portion. The transpiration member is configured to substantially uniformly direct a transpiration substance therethrough toward the combustion chamber, such that the transpiration substance is directed to flow helically about the perimeter and longitudinally between the inlet and outlet portions, for buffering interaction between the combustion product and the transpiration member. Associated systems are also provided.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present patent application is a continuation-in-part of U.S. patentapplication Ser. No. 12/872,364, filed Aug. 31, 2010, which is acontinuation-in-part of U.S. patent application Ser. No. 12/714,074,filed Feb. 26, 2010, which claims priority to U.S. Provisional PatentApplication No. 61/155,755, filed Feb. 26, 2009, and U.S. ProvisionalPatent Application No. 61/299,272, filed Jan. 28, 2010; and also claimspriority to U.S. Provisional Patent Application No. 61/510,356, filedJul. 21, 2011, the disclosures of which are all incorporated herein byreference in their entirety.

BACKGROUND OF THE DISCLOSURE

1. Field of the Disclosure

The present disclosure is directed to apparatuses and systems for thecombustion of a carbonaceous fuel with oxygen at high pressure and hightemperature to produce combustion products which are either oxidizedwith an excess of oxygen, or which contain reducing components and havezero oxygen content. One particular application would be for generationof energy, such as electricity, through the use of a working fluid totransfer energy generated through high efficiency combustion of a fuel.Particularly, such apparatuses and systems can use carbon dioxide orsteam as the working fluid. In another aspect, the apparatuses andsystems may be used to generate a gas containing hydrogen and/or carbonmonoxide.

2. Description of Related Art

It is estimated that fossil fuels will continue to provide the bulk ofthe world's electric power requirements for the next 100 years, whilenon-carbon power sources are developed and deployed. Known methods ofpower generation through combustion of fossil fuels and/or suitablebiomass, however, are plagued by rising energy costs and an increasingproduction of carbon dioxide (CO₂) and other emissions. Global warmingis increasingly seen as a potentially catastrophic consequence ofincreased carbon emissions by the developed and developing nations.Solar and wind power do not appear capable of replacing fossil fuelcombustion in the near term, and nuclear power has dangers associatedwith both proliferation and nuclear waste disposal.

Conventional arrangements for power production from fossil fuels orsuitable biomass are now being increasingly burdened with a requirementfor CO₂ capture at high pressure for delivery to sequestration sites.This requirement is proving difficult to fulfill, however, since presenttechnology only provides for very low thermal efficiencies for even thebest designs for CO₂ capture. Moreover, capital costs for achieving CO₂capture are high, and may thus result in significantly higherelectricity costs compared to systems that emit CO₂ into the atmosphere.Accordingly, there is an ever growing need in the art for apparatusesand methods for high efficiency power generation with a reduction in CO₂emission and/or improved ease of capture and sequestration of producedCO₂.

Oxy-fuel combustion of carbonaceous fuels involves the separation ofsubstantially pure oxygen from air (or otherwise providing suchsubstantially pure oxygen for use in the combustion process) and usingthe oxygen as a combustion medium to produce combustion products whichare substantially free of nitrogen and which comprise carbon dioxide andwater vapor. Current art air and oxy-fuel combustors operate at limitedtemperatures and pressures to prevent excess-temperature damage to thecombustor walls and/or to other system components, such as turbineblades. Limiting the operating temperature and/or pressure may, in someinstances, undesirably lengthen the combustion process and/or require arelatively large combustion volume. In addition, the combustion process,the combustion design, and/or the downstream exhaust gas processingprovisions may also be undesirably dependent on the type of fuelutilized for the process. Further, due to the large volumes ofcombustion gases applied to conventional boiler systems in the currentart, and the exhaust of these gases to atmosphere, current methods ofremoving pollutants from exhaust smokestack gases and proposed oxy-fuelcombustion systems are highly dependent on the detailed design of theplant and on the exact type of fuel burned in the plant. Each type offuel has a contrasting chemical composition and amount of pollutants.Thus, current art undesirably requires that the exhaust gas scrubbersystems or oxy-fuel combustion modifications for each plant becustom-designed specifically to accommodate a particular type of fuelwith a particular chemical composition.

The current art for coal, as an example, generally utilizes a very largesingle combustor equipped with vertical tubular walls orhelically-configured tubular walls in which steam at high pressure isgenerated and superheated in a separate superheater section. Thelarge-size combustor may experience significant heat loss, and ingeneral is subject to damage, as well as fouling of the burners, radiantand convective heat transfer surfaces and other components, from coalash, slag and corrosive components, such as SO_(X), HCl, NO_(X), etc.,in the combustion gases depending on the particular coal used. Suchexemplary shortcomings may require that the entire plant be shut down torepair or replace damaged or corroded parts and/or other components atperiodic intervals, and may thus result in lower availability of theplant and undesirable difficulties in compensating for the lost outputof the plant during down times.

SUMMARY OF THE DISCLOSURE

The above and other needs are addressed by aspects of the presentdisclosure which, according to one particular aspect, provides anapparatus, such as a combustor apparatus, including a mixing arrangementconfigured to mix a carbonaceous fuel with enriched oxygen and a workingfluid to form a fuel mixture. A combustor arrangement defines acombustion chamber having an inlet portion longitudinally spaced apartfrom an opposing outlet portion, wherein the inlet portion is configuredto receive the fuel mixture for combustion within the combustion chamberat a combustion temperature to form a combustion product. The combustionchamber is further configured to direct the combustion productlongitudinally toward the outlet portion. The combustor arrangementcomprises a pressure containment member, and a porous perimetrictranspiration member at least partially defining the combustion chamber,and being at least partially surrounded by the pressure containmentmember. The porous transpiration member is configured to substantiallyuniformly direct a transpiration substance therethrough toward thecombustion chamber, such that the transpiration substance is directed toflow helically about the perimeter thereof and longitudinally betweenthe inlet portion and the outlet portion, to buffer interaction betweenthe combustion product and the porous transpiration member. In someinstances, the flow of the transpiration substance may be directed intothe combustion chamber by the porous transpiration member in asubstantially uniform manner about the perimeter thereof andlongitudinally between the inlet portion and the outlet portion, suchthat the transpiration substance is directed to flow substantiallytangential to the perimeter of the porous transpiration member andhelically thereabout. In addition, the transpiration substance may beintroduced into the combustion chamber to achieve a desired outlettemperature of the combustion product. A transformation apparatus may beconfigured to receive the combustion product, wherein the transformationapparatus is responsive to the combustion product to transform thermalenergy associated therewith into kinetic energy.

In another aspect, oxy-fuel combustion of carbonaceous fuels (and/orhydro-carbonaceous fuels) may also involve the separation ofsubstantially pure oxygen from air (or otherwise providing suchsubstantially pure oxygen) and its use as in the combustion process toproduce combustion products which are substantially free of nitrogen andwhich comprise carbon dioxide and water vapor. The carbon dioxide-richcombustion product (following cooling and water condensation) may thenbe available for subsequent commercial use, such as for enhanced oilrecovery or enhanced natural gas production or disposal in a suitablegeological sequestration site (following compression and purification).Operation of an oxy-fuel power production system at high pressure mayalso allow the carbon dioxide derived from the fuel to be produced at ahigh pressure, resulting in power savings by reducing or eliminating theneed to pressurize the carbon dioxide. Further, high pressure operationmay allow the purified combustion products to be used directly in apower cycle, when mixed with a suitable heated working fluid such as CO₂or steam. The operation of the power system at high pressure may alsolead to reduced volumetric fluid flow rates in the power cycle,resulting in smaller equipment and lower capital costs. The highpressure oxy-fuel combustor with provision for temperature control isanother important aspect. Cycling of a suitable fluid such as combustionproduct gas or carbon dioxide or liquid water or steam (such as from arecycle stream) through a transpiration-cooled and protected wall of thecombustion chamber/space may also serve to control the combustiontemperature. Flow of the transpiration substance through the combustionchamber walls may also serve to eliminate damage to and/or build-up onthe chamber walls due to heat, or ash or liquid slag impingementeffects. Thus, an efficient high pressure, high temperature combustor isprovided which can be adapted to burn a variety of gaseous, liquid, orsolid fuels or fuel mixtures to meet various requirements as part of apower system which can operate at significantly higher efficiencies andlower capital costs than present technology. In some instances, thecombustor may be operated to produce a combustion product comprisinghydrogen and carbon monoxide to be made available to downstreamrequirements, other than power production.

In still a further aspect, the present disclosure generally providesmethods and apparatuses associated with a high pressure, hightemperature, high efficiency, transpiring fluid-protected, oxy-fuelcombustor for use, for example, in power generation, such as incombination with a power cycle using either CO₂ and/or H₂O as a workingfluid. In such an application, the combustor can be operated in anoxidizing mode, whereby the combustion products produced thereby containan oxygen concentration in the range of between about 500 ppm and about3% molar, and a carbon monoxide concentration below about 50 ppm,preferably below about 10 ppm molar. In another aspect, the combustorcan be operated in a reducing mode whereby the combustion productsproduced thereby have near zero oxygen concentration and the combustionproducts contain a concentration of CO and H₂. Operation in the reducingmode can be configured to maximize the production of H₂ and CO, and tominimize the consumption of O₂. The reducing mode of operation may bebeneficial not only for power production, but also for production of H₂or H₂+CO synthesis gas. In particular aspects, the operating pressuremay be in the range of between about 40 bar and about 500 bar, andpreferably at least 80 bar, and the combustion product temperature maybe generally in the range of between about 400° C. and about 3500° C.

In aspects involving power production, a portion of a working fluid isintroduced into the combustor, along with the fuel and oxidant (i.e.,enriched oxygen), for combustion, such that a high pressure, hightemperature fluid stream (combustion product) is produced comprising theworking fluid and the combustion products. The working fluid can beintroduced through the transpiration-protected walls of the combustionchamber and/or through additional injection points about the combustionchamber. The working fluid, following the combustion process and mixingwith the combustion products through transpiration, may have atemperature in a range suitable (i.e., low enough) for introductiondirectly into a power generation device, such as a turbine. In suchinstances, the total quantity of working fluid introduced into thecombustor, as a diluent to the combustion products, may be adjusted toprovide an exit temperature for the total working fluid stream leavingthe combustor which is suitable for the operating inlet temperature andpressure of the power turbine. Advantageously, the fluid stream may bemaintained at a relatively high pressure during expansion in the turbinesuch that the pressure ratio across the turbine (i.e., the ratio of thepressure at the inlet to the pressure at the outlet of the turbine) isless than about 12. The fluid stream can also be further processed toseparate the components of the fluid stream, wherein such processing caninclude passing the fluid stream through a heat exchanger. Inparticular, the expanded working fluid (at least a portion of which maybe recycled from the fluid stream) can be passed through the same heatexchanger to heat the high pressure working fluid prior to introductionof the same into the combustor. In certain aspects, the disclosureprovides a high pressure oxy-fuel combustor for power production systemsthat can produce power at high efficiency with low capital cost and alsocan produce substantially pure CO₂ at pipeline pressure for commercialuse or sequestration. The CO₂ also may be recycled into the powerproduction system.

In other aspects, the disclosed combustion systems and methods may beconfigured to use a wide variety of fuel sources. For example, the highefficiency combustor according to the disclosure may use gaseous (e.g.,natural gas or coal derived gases), liquid (e.g., hydrocarbons, bitumen)and/or solid (e.g., coal, lignite, pet-coke) fuels. Even other fuels, asotherwise described herein, could be used, such as algae, biomass, orany other suitable combustible organic materials.

In other aspects, the methods and systems of the present disclosure,when combined with power systems with CO₂ capture at pipeline pressuremay be useful in that the combined system may exceed the best efficiencyof current coal-fired steam cycle power stations that do not provide forthe capture of CO₂. Such current power stations can provide, at best,for example, about 45% efficiency (L.H.V.) with 1.7 inches mercurycondenser pressure using a bituminous coal. Aspects of the presentsystem may exceed such efficiency, for example, while delivering CO₂ at200 bar pressure.

In still another aspect, the present disclosure may provide the abilityto reduce the physical size and capital cost of a power generationsystem compared to current technologies using a similar fuel. Thus, themethods and systems of the present disclosure can contribute to orotherwise facilitate significantly reduced construction costs associatedwith power production systems, and the relatively high efficiency ofcertain system combinations can lead to reduced costs of electricity orenergy production, as well as reduced use of fossil fuels.

In one particular aspect, the present disclosure is directed to a methodof power generation incorporating the use of a working fluid, such asCO₂ and/or H₂O. In some aspects, the method may comprise introducingheated, compressed CO₂ and/or superheated steam into a fuel combustor.Preferably, the CO₂ and/or steam can be introduced into a combustoroperating at a pressure of at least about 80 bar. The CO₂ and/or H₂O canbe introduced into the combustor at two or more separate locations. Partof the CO₂ and/or H₂O can be mixed with the O₂ and the solid, liquid,gaseous or supercritical fuel so that the combustion temperature withinthe combustion chamber can be determined based on the desired designvalue for the combustor. The rest of the heated CO₂ and/or superheatedsteam is then introduced into the combustion chamber to cool thecombustion products by direct mixing therewith to achieve a desiredtotal exit fluid stream temperature of between about 400° C. and about3500° C., which may be required by the power production system. Undersuch conditions, the CO₂ and/or H₂O can mix with combustion gasesresulting from combustion of the fuel, with an oxidant such as oxygen ata purity greater than 85% molar, to produce a fluid stream comprisingCO₂ and/or H₂O at the desired temperature. In particular aspects, theexit fluid stream temperature may be in the range of between about 400°C. and about 3500° C. In other aspects, the exit fluid stream may beexpanded across a turbine to generate power (i.e., generate electricityvia the energy imparted to the turbine).

In certain aspects, it may be useful to heat the working fluid to aneven greater temperature prior to introduction into the combustor. Forexample, the CO₂ and/or H₂O may be heated to a temperature of at leastabout 200° C. to about 700° C. prior to introduction into the combustor.In other aspects, the CO₂ and/or H₂O may be heated to a temperature ofbetween about 700° C. and about 1000° C. prior to introduction into thecombustor. In some aspects, such heating can be carried out using a heatexchanger arrangement. As further disclosed herein, the same heatexchanger may be used to cool the fluid stream exiting the powergeneration turbine.

Similarly, the combustor may be usefully operated at a higher pressureto produce a working fluid capable of achieving a very high efficiencyin a power production cycle. For example, the combustor and theintroduced portion of the working fluid CO₂ and/or H₂O may bepressurized to at least about 200 bar. In other aspects, the pressuremay be between about 200 bar and about 500 bar.

In certain aspects, the portion of the working fluid introduced into thecombustor can be a recycled stream of substantially pure CO₂ so that anywater content in the working fluid originates from the fuel. Of course,CO₂ from an external source could be used as the working fluid.

The fluid stream exiting from the combustor may comprise the CO₂ and/orH₂O working fluid as well as one or more other components, such asproducts of combustion derived from the fuel or the combustion process.The exiting fluid stream can contain components such as H₂O, SO₂, SO₃,NO, NO₂, Hg, HCl plus excess oxygen in the range of between about 300ppm and about 3% molar. In other aspects, the exiting fluid stream cancontain at least varying fractions of H₂ and CO and have substantiallyzero O₂ content.

The combustor may comprise an inlet nozzle arrangement through which thefuel plus the oxygen plus a portion of the working fluid is introducedinto the combustor and where combustion is initiated and takes place ina stable manner, in either an oxidizing or reducing mode, over a desiredfuel flow range, which is typically between about 50% and about 100% ofdesign capacity. In certain aspects, the operating pressure may be aboveabout 150 bar and, at this pressure, the oxygen can be introduced as asingle phase mixture with CO₂ and a fuel such as natural gas, or aliquid such as a hydrocarbon distillate, to achieve a required adiabaticflame temperature. If the CO₂ at this high pressure is at a temperaturebelow about 100° C., the density of the CO₂ is high enough to be used tosupport a significant fraction of powdered coal to form a slurry,wherein the slurry can then be pumped by a high pressure pump to therequired combustion pressure and flow in a pipe, and to a mixing pointwhere the supercritical mixture of CO₂ and oxygen is added to achieve arequired adiabatic flame temperature in the combustor. The premixedfuel, diluent CO₂ and oxygen should desirably be at a combinedtemperature which is below the auto-ignition temperature of the system.The temperature of the CO₂ stream may be adjusted to meet thiscriterion. The inlet nozzle can comprise an array of holes in aninjector plate, each of which will produce a fine jet of fluid resultingin rapid heat transfer and combustion, thereby producing a stablecombustion zone. Hole sizes can be in the range of between about 0.5 mmand about 3 mm in diameter.

The walls of the combustion chamber may be lined with a layer of porousmaterial through which is directed and flows a second part of the CO₂and/or H₂O diluent stream. The flow of fluid through this poroustranspiration layer, and optionally through additional provisions, isconfigured to achieve the required total exit fluid stream outlettemperature of between about 400° C. and about 3500° C. This flow mayalso serve to cool the transpiration member to a temperature below themaximum allowable operational temperature of the material forming thetranspiration member. The transpiration substance, such as the CO₂and/or H₂O diluent stream, may also serve to prevent impingement of anyliquid or solid ash materials or other contaminants in the fuel whichmight corrode, foul, or otherwise damage the walls. In such instances,it may be desirable to use a material for the transpiration member witha reasonable (low) thermal conductivity so that incident radiant heatcan be conducted radially outwards through the porous transpirationmember and then be intercepted by convective heat transfer from thesurfaces of the porous layer structure to the fluid passing radiallyinwards through the transpiration layer. Such a configuration may allowthe subsequent part of the diluent stream directed through thetranspiration member to be heated to a temperature in the range ofbetween about 500° C. and about 1000° C., while simultaneouslymaintaining the temperature of the porous transpiration member withinthe design range of the material used therefor. Suitable materials forthe porous transpiration member may include, for example, porousceramics, refractory metal fiber mats, hole-drilled cylindricalsections, and/or sintered metal layers or sintered metal powders. Asecond function of the transpiration member may be to ensure asubstantially even radially inward flow of diluents transpirationsubstance, as well as longitudinally along the combustor, to achievegood mixing between the second part of the diluent stream and thecombustion product while promoting an even axial flow of along thelength of the combustion chamber. A third function of the transpirationmember is to achieve a velocity of diluent fluid radially inward so asto provide a buffer for or otherwise intercept solid and/or liquidparticles of ash or other contaminants within the combustion productsfrom impacting the surface of the transpiration layer and causingblockage or other damage. Such a factor may only be of importance, forexample, when combusting a fuel, such as coal, having a residual inertnon-combustible residue. The inner wall of the combustor pressure vesselsurrounding the transpiration member may also be insulated to isolatethe high temperature second diluent stream within the combustor.

Coal or other fuels with an incombustible residue may be introduced intothe combustor as a slurry in water or, preferably, a slurry in liquidCO₂. The liquid portion of the slurry leaves the power system at nearambient temperature and at the lowest pressure in the power cycle. Thedifference in enthalpy per mole between slurry inlet condition and thegas outlet condition, in such instances, may be about 10 kcal/gm-mol forH₂O and about 2.78 kcal/gm-mol for CO₂, giving a significantly higherefficiency for a CO₂ slurrying fluid. Little additional energy isrequired in a high pressure power cycle with CO₂ as the working fluid toproduce liquid CO₂ at temperatures in the range of between about −30° C.and about 10° C.

The combustion temperature of fuels, generally solids such as coal,producing incombustible residue, is preferably in the range of betweenabout 1800° C. and about 3000° C. In such conditions, the ash or othercontaminants will be in the form of liquid slag droplets originatingfrom the fuel particles in the slurry fuel feed. These liquid slagdroplets must be removed efficiently in order to prevent contaminationof the power turbine or other downstream processes. Removal may beaccomplished, for example, using cyclone separators, impingementseparators, or beds of graded refactory granular filters arranged in anannular configuration, or combinations thereof. In particular aspects,the droplets may be removed from the high temperature working fluidstream by a series of cyclone separators. To achieve efficient removal,there is preferably at least 2 and preferably 3 cyclone separators inseries. The removal efficiency may be enhanced by a number of factors.For example, the removal temperature can be adjusted to ensure that theslag viscosity is low enough to remove a free draining liquid slag fromthe separators. It may sometimes be necessary to carry out the slagremoval at an intermediate temperature, between the combustiontemperature and the final exit fluid stream temperature. In such cases,the final exit fluid stream outlet temperature may be achieved by mixinga portion of the recycled working fluid (the transpiration substance)directly with the fluid stream leaving the slag removal system. Thediameter of the cyclone separators should desirably be relatively low(i.e., in the range of between about 20 cm and about 50 cm in diameter),while the diameter of the slag droplets should be high enough to providegood separation efficiency. Such conditions may be achieved, forexample, by grinding the coal fuel to achieve a high fraction of >50microns particle diameter. The coal is preferably particulated tobetween about 50 microns and about 100 microns in average particlediameter, which may result in a minimal fraction of slag particles below10 microns diameter being present in the exit working fluid flow. Insome instances, the cyclone separators may be followed by an annularfilter disposed immediately upstream of the turbine.

In particular aspects, a residence time for combustion products in thesystem may be in the range 0.2 second to 2 seconds for natural gas and0.4 seconds to 4 seconds for a bituminous coal.

The fluid stream exiting the combustor may exhibit a variety ofdifferent characteristics. For example, the fluid stream may comprise anoxidizing fluid. As such, the fluid stream may comprise one or morecomponents that may be rapidly oxidized (e.g., combusted) by theaddition of an oxidant (e.g., O₂). In some aspects, the fluid stream maybe a reducing fluid comprising one or more components selected from thegroup consisting of H₂, CO, CH₄, H₂S, and combinations thereof.Operation of the system in the reducing mode will be generally similarto the oxidizing mode except that the proportion of the secondarydiluent will be progressively reduced as the fraction of fuel convertedto H₂+CO increases. It may also be necessary to increase the averageresidence time for combustion products progressively to a range ofbetween about 2.5 seconds and about 4.5 seconds for natural gas fuel, asthe conversion to H₂+CO increases to the maximum, and between about 6seconds and about 10 seconds for a bituminous coal.

The above and other aspects thus address the identified needs andprovide advantages as otherwise detailed herein.

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus described the disclosure in general terms, reference willnow be made to the accompanying drawings, which are not necessarilydrawn to scale, and wherein:

FIG. 1 is a schematic illustration of a transpiration-cooled combustorapparatus, according to certain aspects of the present disclosure;

FIG. 1A is a schematic illustration of a combustor temperature profilealong the length of the combustion chamber, according to certain aspectsof the present disclosure;

FIG. 2 is a schematic illustration of an exemplary cross-section of awall of a transpiration member in a combustor apparatus, according tocertain aspects of the present disclosure;

FIG. 2A is a schematic illustration of an exemplary cross-section of awall of a transpiration member in a combustor apparatus, according tocertain aspects of the present disclosure, taken perpendicularly to thelongitudinal axis thereof and illustrating a pore/perforationconfiguration for providing a helical flow of a transpiration fluid;

FIG. 2B is a schematic illustration of an exemplary cross-section of awall of a transpiration member in a combustor apparatus, according tocertain aspects of the present disclosure, illustrating an angularpore/perforation configuration for facilitating a helical flow of atranspiration fluid;

FIG. 2C is a schematic illustration of an exemplary cross-section of awall of a transpiration member in a combustor apparatus, according tocertain aspects of the present disclosure, illustrating fusedlongitudinal strips of the transpiration member for facilitating ahelical flow of a transpiration fluid;

FIG. 2D is a schematic illustration of a shield structure configured tobe arranged/inserted with respect to the transpiration member shown inFIG. 2C, according to certain aspects of the present disclosure, forfacilitating a helical flow of a transpiration fluid;

FIG. 2E is a schematic illustration of a helical flow of a transpirationfluid within a combustion chamber of a combustor apparatus, according tocertain aspects of the present disclosure;

FIG. 2F is a schematic illustration of a Coanda effect which may beimplemented to facilitate a helical flow of a transpiration fluid withina combustion chamber of a combustor apparatus, according to certainaspects of the present disclosure;

FIG. 2G is a schematic illustration of serially-arranged, opposinghelical flows of a transpiration fluid within a combustion chamber of acombustor apparatus, according to certain aspects of the presentdisclosure;

FIGS. 3A and 3B schematically illustrate a hot fit process for atranspiration member assembly of a combustor apparatus, according tocertain aspects of the present disclosure;

FIG. 4 schematically illustrates a combustion product contaminantremoval apparatus, according to certain aspects of the presentdisclosure;

FIG. 5 is a schematic plot showing trajectories of ash particles as afunction of average particle size and transpiration substance flowrates, according to certain aspects of the present disclosure; and

FIG. 6 is a schematic of an adaptable power generation system, accordingto certain aspects of the present disclosure.

DETAILED DESCRIPTION OF THE DISCLOSURE

The present disclosure now will be described more fully hereinafter withreference to the accompanying drawings, in which some, but not allaspects of the disclosure are shown. Indeed, this disclosure may beembodied in many different forms and should not be construed as limitedto the aspects set forth herein; rather, these aspects are provided sothat this disclosure will satisfy applicable legal requirements. Likenumbers refer to like elements throughout.

One aspect of a combustor apparatus capable of operating with a solidfuel, according to the present disclosure, is schematically illustratedin FIG. 1, the combustor apparatus being generally indicated by thenumeral 220. In this example, the combustor apparatus 220 may beconfigured to combust a particulate solid such as coal to form acombustion product, though any other suitable combustible organicmaterial, as disclosed herein, may also be used as a fuel. Thecombustion chamber 222 may be defined by a transpiration member 230,which is configured to direct a transpiration substance, such as atranspiration fluid, therethrough into the combustion chamber 222 (i.e.,to facilitate transpiration cooling and/or to buffer interaction betweenthe combustion product and the transpiration member 230). One skilled inthe art will appreciate that the transpiration member 230 may besubstantially cylindrical, so as to define a substantially cylindricalcombustion chamber 222 having an inlet portion 222A and an opposingoutlet portion 222B. The transpiration member 230 may be at leastpartially surrounded by a pressure containment member 338. The inletportion 222A of the combustion chamber 222 may be configured to receivea fuel mixture from a mixing arrangement, generally indicated by thenumeral 250. According to particular aspects, the fuel mixture iscombusted within the combustion chamber 222 at a particular combustiontemperature to form a combustion product, wherein the combustion chamber222 is further configured to direct the combustion product toward theoutlet portion 222B. A heat removal device 350 (see, e.g., FIG. 2) maybe associated with the pressure containment member 338 and configured tocontrol a temperature thereof. In particular instances, the heat removaldevice 350 may comprise a heat transfer jacket at least partiallydefined by a wall 336 opposing the pressure containment member 338,wherein a liquid may be circulated in water-circulating jackets 337defined therebetween. In one aspect, the circulated liquid may be water.

The mixing arrangement 250 is configured to mix a carbonaceous fuel 254with enriched oxygen 242 and a working fluid 236 to form a fuel mixture200. The carbonaceous fuel 254 may be provided in the form of a solidcarbonaceous fuel, a liquid carbonaceous fuel, and/or a gaseouscarbonaceous fuel. The enriched oxygen 242 may be oxygen having a molarpurity of greater than about 85%. The enriched oxygen 242 may besupplied, for example, by any air separation system/technique known inthe art, such as, for example, a cryogenic air separation process, or ahigh temperature ion transport membrane oxygen separation process (fromair), could be implemented. The working fluid 236 may be carbon dioxideand/or water. In instances where the carbonaceous fuel 254 is aparticulate solid, such as powdered coal 254A, the mixing arrangement250 may be further configured to mix the particulate solid carbonaceousfuel 254A with a fluidizing substance 255. According to one aspect, theparticulate solid carbonaceous fuel 254A may have an average particlesize of between about 50 microns and about 200 microns. According to yetanother aspect, the fluidizing substance 255 may comprise water and/orliquid CO₂ having a density of between about 450 kg/m³ and about 1100kg/m³. More particularly, the fluidizing substance 255 may cooperatewith the particulate solid carbonaceous fuel 254A to form a slurry 250Ahaving, for example, between about 25 weight % and about 95 weight % ofthe particulate solid carbonaceous fuel 254A or, in other instances,between about 25 weight % and about 60 weight % of the particulate solidcarbonaceous fuel 254A. Though the oxygen 242 is shown in FIG. 2 asbeing mixed with the fuel 254 and the working fluid 236 prior tointroduction to the combustion chamber 222, one skilled in the art willappreciate that, in some instances, the oxygen 242 may be separatelyintroduced into the combustion chamber 222, as necessary or desired.

The mixing arrangement 250, in some aspects, may comprise, for example,an array of spaced apart injection nozzles (not shown) arranged about anend wall 223 of the transpiration member 230 associated with the inletportion 222A of the cylindrical combustion chamber 222. Injecting thefuel/fuel mixture into the combustion chamber 222 in this manner mayprovide, for example, a large surface area of the injected fuel mixtureinlet stream which may, in turn, facilitate rapid heat transfer to theinjected fuel mixture inlet stream by radiation. The temperature of theinjected fuel mixture may thus be rapidly increased to the ignitiontemperature of the fuel (i.e., the coal particles) and may thus resultin a compact combustion. The injection velocity of the fuel mixture maybe in the range, for example, of between about 10 msec and about 40m/sec, though these values may depend on many factors, such as theconfiguration of the particular injection nozzles. Such an injectionarrangement may take many different forms. For example, the injectionarrangement may comprise an array of holes, for instance, in the rangeof between about 0.5 mm and about 3 mm diameter, wherein the fuelinjected would be injected therethrough at a velocity of between about10 m/s and about 40 m/s.

Such a “direct injection” of the fuel/fuel mixture through generallystraight, linear, and/or unobstructed passages directly into thecombustion chamber 222 may, for example, reduce wear, corrosion, and/orparticulate accumulation, particularly in instances where the fuelincludes a solids component (i.e., coal slurry in a partial oxidation(PDX) combustor). In some instances, though, it may be advantageous forthe fuel/fuel mixture to deviate from the straight uniform flow onceinside the combustion chamber 222. For example, it may be advantageous,in some aspects, to cause the fuel/fuel mixture to be swirled orotherwise disrupted from the straight uniform flow so as to, forinstance, promote mixing of the fuel/fuel mixture, thus resulting in amore efficient combustion process.

In other aspects, the mixing arrangement 250 may be remote with respectto or otherwise separate from the combustion chamber 222. For example,in some aspects, the mixing arrangement 250 may be configured to directthe fuel mixture 200 to a burner device 300 extending into thecombustion chamber 222 through the pressure containment member 338 andthe transpiration member 230. The burner device 300 may be configured tointroduce the fuel/fuel mixture into the combustion chamber 222 in astraight, substantially uniform flow, similar to the “direct injection”arrangement. That is, the burner device 300 may be configured to receivethe fuel/fuel mixture from the mixing arrangement 250 and to direct asubstantially uniform linear flow of the fuel/fuel mixture into theinlet portion 222A of the combustion chamber 222. However, in someinstances (i.e., using a fuel that does not include solid particulates),the burner device 300 may include appropriate provisions for causing orotherwise inducing the fuel/fuel mixture to swirl or be swirled uponbeing directed into the combustion chamber 222, as will be appreciatedby one skilled in the art. That is, the burner device 300 may beconfigured to swirl or otherwise disrupted from the straight uniformflow of the fuel/fuel mixture upon introduction thereof into thecombustion chamber 222. In some aspects, the burner device 300 may beconfigured to receive the fuel/fuel mixture from the mixing arrangement250 and to direct the fuel/fuel mixture into the inlet portion 222A ofthe combustion chamber 222, while inducing swirl of the fuel/fuelmixture directed into the combustion chamber 222. More particularly, theburner device 300 may be configured to induce swirl of the fuel/fuelmixture upon exit of the fuel/fuel mixture therefrom into the combustionchamber 222.

As more particularly shown in FIG. 2, the combustion chamber 222 isdefined by the transpiration member 230, which may be at least partiallysurrounded by a pressure containment member 338. In some instances, thepressure containment member 338 may further be at least partiallysurrounded by a heat transfer jacket 336, wherein the heat transferjacket 336 cooperates with the pressure containment member 338 to defineone or more channels 337 therebetween, through which a low pressurewater stream may be circulated. Through an evaporation mechanism, thecirculated water may thus be used to control and/or maintain a selectedtemperature of the pressure containment member 338, for example, in arange of between about 100° C. and about 250° C. In some aspects, aninsulation layer 339 may be disposed between the transpiration member230 and the pressure containment member 338.

In some instances, the transpiration member 230 may comprise, forexample, an outer transpiration member 331 and an inner transpirationmember 332, the inner transpiration member 332 being disposed oppositethe outer transpiration member 331 from the pressure containment member338, and defining the combustion chamber 222. The outer transpirationmember 331 may be comprised of any suitable high temperature-resistantmaterial such as, for example, steel and steel alloys, includingstainless steel and nickel alloys. In some instances, the outertranspiration member 331 may be configured to define first transpirationfluid supply passages 333A extending therethrough from the surfacethereof adjacent to the insulation layer 339 to the surface thereofadjacent to the inner transpiration member 332. The first transpirationfluid supply passages 333A may, in some instances, correspond to secondtranspiration fluid supply passages 333B defined by the pressurecontainment member 338, the heat transfer jacket 336 and/or theinsulation layer 339. The first and second transpiration fluid supplypassages 333A, 333B may thus be configured to cooperate to direct atranspiration substance, such as a transpiration fluid 210, therethroughto the inner transpiration member 332. In some instances, as shown, forexample, in FIG. 1, the transpiration fluid 210 may comprise the workingfluid 236, and may be obtained from the same source associatedtherewith. The first and second transpiration fluid supply passages333A, 333B may be insulated, as necessary, for delivering thetranspiration fluid 210 (i.e., CO₂) in sufficient supply and at asufficient pressure such that the transpiration fluid 210 is directedthrough the inner transpiration member 332 and into the combustionchamber 222. Such measures involving the transpiration member 230 andassociated transpiration fluid 210, as disclosed herein, may allow thecombustor apparatus 220 to operate at the relatively high pressures andrelatively high temperatures otherwise disclosed herein.

In this regard, the inner transpiration member 332 may be comprised of,for example, a porous ceramic material, a perforated material, alaminate material, a porous mat comprised of fibers randomly orientatedin two dimensions and ordered in the third dimension, or any othersuitable material or combinations thereof exhibiting the characteristicsrequired thereof as disclosed herein, namely multiple flow passages orpores or other suitable openings 335 for receiving and directing thetranspiration fluid through the inner transpiration member 332.Non-limiting examples of porous ceramic and other materials suitable forsuch transpiration-cooling systems include aluminum oxide, zirconiumoxide, transformation-toughened zirconium, copper, molybdenum, tungsten,copper-infiltrated tungsten, tungsten-coated molybdenum, tungsten-coatedcopper, various high temperature nickel alloys, and rhenium-sheathed orcoated materials. Sources of suitable materials include, for exampleCoorsTek, Inc., (Golden, Colo.) (zirconium); UltraMet Advanced MaterialsSolutions (Pacoima, Calif.) (refractory metal coatings); Osram Sylvania(Danvers, Mass.) (tungsten/copper); and MarkeTech International, Inc.(Port Townsend, Wash.) (tungsten). Examples of perforated materialssuitable for such transpiration-cooling systems include all of the abovematerials and suppliers (where the perforated end structures may beobtained, for example, by perforating an initially nonporous structureusing methods known in the manufacturing art). Examples of suitablelaminate materials include all of the above materials and suppliers(where the laminate end structures may be obtained, for example, bylaminating nonporous or partially porous structures in such a manner asto achieve the desired end porosity using methods known in themanufacturing art).

In still further aspects, the inner transpiration member 332 may extendfrom the inlet portion 222A to the outlet portion 222B of thetranspiration member 230. In some instances, the perforated/porousstructure of the inner transpiration member 332 may extend substantiallycompletely (axially) from the inlet portion 222A to the outlet portion222B such that the transpiration fluid 210 is directed intosubstantially the entire length of the combustion chamber 222. That is,substantially the entirety of the inner transpiration member 332 may beconfigured with a perforated/porous structure such that substantiallythe entire length of the combustion chamber 222 is transpiration-cooled.More particularly, in some aspects, the cumulative perforation/pore areamay be substantially equal to the surface area of the innertranspiration member 332. That is, the ratio of pore area to total wallarea (% porosity) may be on the order of, for example 50%. In stillother aspects, the perforations/pores may be spaced apart at anappropriate density such that substantially uniform distribution of thetranspiration substance from the inner transpiration member 332 into thecombustion chamber 222 is achieved (i.e., no “dead spots” where the flowor presence of the transpiration substance 210 is lacking). In oneexample, the inner transpiration member 332 may include an array ofperforations/pores on the order of 250×250 per square inch, so as toprovide about 62,500 pores/in², with such perforations/pores beingspaced about 0.004 inches (about 0.1 mm) apart. One skilled in the artwill appreciate, however, that the configuration of the pore array maybe varied, as appropriate, so as to be adaptable to other systemconfiguration parameters or to achieve a desired result such as, forinstance, a desired pressure drop versus flow rate across thetranspiration member 230. In a further example, the pore array may varyin size from about 10×10 per square inch to about 10,000×10,000 persquare inch, with porosity percentages varying from between about 10% toabout 80%.

FIGS. 3A and 3B illustrate that, in one aspect of a combustor apparatus220, the structure defining the combustion chamber 222 may be formedthrough a “hot” interference fit between the transpiration member 230and the surrounding structure, such as the pressure containment member338 or the insulation layer 339 disposed between the transpirationmember 230 and the pressure containment member 338. For example, whenrelatively “cold,” the transpiration member 230 may be dimensioned to besmaller, radially and/or axially, with respect to the surroundingpressure containment member 338. As such, when inserted into thepressure containment member 338, a radial and/or axial gap may bepresent therebetween (see, e.g., FIG. 3A). Of course, such dimensionaldifferences may facilitate insertion of the transpiration member 230into the pressure containment member 338. However, when heated, forexample, toward the operational temperature, the transpiration member230 may be configured to expand radially and/or axially to reduce oreliminate the noted gaps (see, e.g., FIG. 3B). In doing so, aninterference axial and/or radial fit may be formed between thetranspiration member 230 and the pressure containment member 338. Ininstances involving a transpiration member 230 with an outertranspiration member 331 and an inner transpiration member 332, such aninterference fit may place the inner transpiration member 332 undercompression. As such, suitable high temperature resistant brittlematerials, such as a porous ceramic, may be used to form the innertranspiration member 332.

With the inner transpiration member 332 thus configured, thetranspiration substance 210 may comprise, for example, carbon dioxide(i.e., from the same source as the working fluid 236) directed throughthe inner transpiration member 332 such that the transpiration substance210 forms a buffer layer 231 (i.e., a “vapor wall”) immediately adjacentto the inner transpiration member 332 within the combustion chamber 222,wherein the buffer layer 231 may be configured to buffer interactionbetween the inner transpiration member 332 and the liquefiedincombustible elements and heat associated with the combustion product.That is, in some instances, the transpiration fluid 210 can be deliveredthrough the inner transpiration member 332, for example, at least at thepressure within the combustion chamber 222, wherein the flow rate of thetranspiration fluid 210 (i.e., CO₂ stream) into the combustion chamber222 is sufficient for the transpiration fluid 210 to mix with and coolthe combustion products to form an exit fluid mixture at a sufficienttemperature with respect to the inlet requirement of the subsequentdownstream process (i.e., a turbine may require an inlet temperature,for instance, of about 1225° C.), but wherein the exit fluid mixturetemperature remains sufficiently high to maintain slag droplets or othercontaminants in the fuel in a fluid or liquid state. The liquid state ofthe incombustible elements of the fuel may facilitate, for example,separation of such contaminants from the combustion product in liquidform, preferably in a free flowing, low viscosity form, which will beless likely to clog or otherwise damage any removal system implementedfor such separation. In practice, such requirements may depend onvarious factors such as the type of solid carbonaceous fuel (i.e., coal)employed and the particular characteristics of the slag formed in thecombustion process. That is, the combustion temperature within thecombustion chamber 222 is preferably such that any incombustibleelements in the carbonaceous fuel are liquefied within the combustionproduct.

In particular aspects, the porous inner transpiration member 332 is thusconfigured to direct the transpiration fluid/substance into thecombustion chamber 222 in a radially inward manner so as to form a fluidbarrier wall or buffer layer 231 about the surface of the innertranspiration member 332 defining the combustion chamber 222 (see, e.g.,FIG. 2). In one particular aspect, the porous inner transpiration member332 is thus configured to direct the transpiration fluid into thecombustion chamber 222, such that the transpiration substance 210 entersthe combustion chamber 222 at a substantially right angle (90°) withrespect to the inner surface of the inner transpiration member 332.Among other advantages, the introduction of the transpiration substance210 at the substantially right angle with respect to the innertranspiration member 332 may facilitate or otherwise enhance the effectof directing slag liquid or solid droplets or other contaminants or hotcombustion fluid vortices away from the inner surface of the innertranspiration member 332. Reducing, minimizing, or otherwise preventingcontact between the slag liquid or solid droplets and the innertranspiration member 332 may, for instance, prevent the coalescence ofsuch contaminants into larger droplets or masses, which may be known tooccur upon contact between droplets/particles and solid walls, and whichmay cause damage to the inner transpiration member 332. The introductionof the transpiration substance 210 at a substantially right angle withrespect to the inner transpiration member 332 may thus facilitate orotherwise enhance the prevention of the formation of combustion fluidvortices in proximity to the inner transpiration member 332 withsufficient velocity or momentum to impinge upon and potentially damagethe inner transpiration member 332.

As previously disclosed, it may be advantageous, in other instances, toinduce swirl, or other disruption of the straight uniform flow, into thefuel/fuel mixture upon the fuel/fuel mixture being directed into thecombustion chamber 222. By accomplishing such flow disruption after thefuel/fuel mixture has been delivered into the combustion chamber 222,drawbacks associated with nozzles or other burner devices or deliverydevices used to cause such flow disruption prior to delivery of thefuel/fuel mixture into the combustion chamber 222 may be avoided orminimized. However, one skilled in the art will appreciate that, in someinstances, such post-introduction of the fuel/fuel mixture may sometimesbe necessary and/or desired in conjunction with such fuel/fuel mixturedelivery devices imparting disruption of the pre-introduction flowthereof.

As such, in some aspects of the present disclosure, at least the innertranspiration member 332 may be configured to substantially uniformlydirect the transpiration fluid 210 therethrough toward the combustionchamber 222, such that the transpiration fluid 210 is directed to flowhelically (see, e.g., FIG. 2E) about the perimeter 221 (see, e.g., FIG.2A) thereof and longitudinally between the inlet portion 222A and theoutlet portion 222B, to form the fluid barrier wall or buffer layer 231about the surface of the inner transpiration member 332 to bufferinteraction between the transpiration member 332 and the combustionproducts and/or the fuel mixture. More particularly, in some aspects, atleast the inner transpiration member 332 is configured to direct thetranspiration fluid 210 therethrough and into the combustion chamber222, substantially uniformly about the perimeter 221 thereof andlongitudinally between the inlet portion 222A and the outlet portion222B, such that the transpiration fluid 210 is directed to flowsubstantially tangential to the perimeter 221 of the inner transpirationmember 332 and helically (i.e., in a spiral or coil form) thereabout, asshown, for example, in FIGS. 2A and 2E. For example, theperforations/pores 335 defined by the inner transpiration member 332 maybe arcuate or angled upon extending between the outer surface and theinner surface thereof (see, e.g., FIG. 2A) so as to direct thetranspiration fluid 210 flowing therethrough substantially tangential toor otherwise along the perimeter 221 of the combustion chamber 222.

In another example, pores along longitudinal strips of the innertranspiration member 332 may be fused/closed so as to facilitate thetranspiration fluid 210 flowing therethrough substantially tangential toor otherwise along the perimeter 221 of the combustion chamber 222 (see,e.g., FIG. 2C). In other instances, in addition to or instead of fusinglongitudinal strips of the inner transpiration member 332, a shieldstructure 224 (i.e., a metal or ceramic shield arrangement) could bearranged/inserted with respect to the inner transpiration member 332 asshown, for example, in FIG. 2C, so as to block particular porous wallsurfaces to prevent radial flow therethrough, without blocking othersurfaces facilitating flow of the transpiration fluid 210 substantiallytangential to or otherwise along the perimeter 221 of the combustionchamber 222 (see, e.g., FIGS. 2C and 2D). Though the structure 224 orthe fusing process may be configured to direct the transpiration fluid210 substantially tangential to or otherwise along the perimeter 221 ofthe combustion chamber 222, once the flow thereof interacts with thelongitudinal combustion flow, the vector sum flow will becomesubstantially helical. One skilled in the art, however, will appreciatethat there may be many other ways in which to configure the innertranspiration member 332 to accomplish the flow of the transpirationfluid 210 substantially tangential to or otherwise along the perimeter221 of the combustion chamber 222.

In yet another example, the perforations/pores 335 may be configured toimpart a Coanda effect on the transpiration fluid 210 (see, e.g., FIG.2F) directed therethrough so as to direct the transpiration fluid 210flowing therethrough substantially tangential to or otherwise along theperimeter 221 of the combustion chamber 222. In such instances, the flowof the fuel/fuel mixture and/or the combustion products from the inletportion 222A toward the outlet portion 222B may cause the flow of thetranspiration fluid 210 to likewise be directed longitudinally towardthe outlet portion 222B to thereby effectuate the helical or spiral flowof the transpiration fluid 210 along the combustion chamber 222. In suchinstances, the pores/perforations 335 defined by the inner transpirationmember 332 may extend therethrough substantially perpendicular to thelongitudinal axis of the combustion chamber 222 as shown, for example,in FIG. 2. However, in other instances, the pores/perforations 335 maybe angled toward the outlet portion 222B (see, e.g., FIG. 2B) to promotethe helical/spiral flow of the transpiration fluid 210 and/or mixingwith the fuel mixture/combustion products, or the pores/perforations 335may be angled toward the inlet portion 222A (not shown) to otherwiseaffect the interaction between the transpiration fluid 210 and the fuelmixture and/or the combustion products (i.e., promote mixing or controlcombustion rate). Accordingly, such manipulation of the flow of the fuelmixture/combustion products along the combustion chamber 222 may providedesired effects in and control of the combustion characteristics and/orkinetics during the combustion process, in some instances, without aphysical device otherwise affecting the substantially straight anduniform flow of the fuel/fuel mixture into the combustion chamber 222.Such an arrangement, namely the absence of physical devices foraffecting the flow of the fuel mixture/combustion products, mayotherwise be advantageous, for example, in eliminating accumulationlocales for particulates contained in the fuel mixture and/or thecombustion products, as will be appreciated by one skilled in the art.

In so manipulating the flow of the fuel mixture/combustion products, soas to impart or otherwise induce swirling thereof within the combustionchamber 222, the burner device 300 and/or the transpiration member 230may be configured in different arrangements. For example, in one aspect,the burner device 300 may be configured to receive the fuel/fuel mixturefrom the mixing arrangement 250 and to direct the fuel/fuel mixture intothe inlet portion 222A of the combustion chamber 222 in a flow directiongenerally opposite to the helical flow of the transpiration fluid 210.In another aspect, the burner device 300 may be configured to receivethe fuel/fuel mixture from the mixing arrangement 250 and to direct thefuel/fuel mixture into the inlet portion 222A of the combustion chamber222 in a direction consistent with (i.e., in the same direction as) thehelical flow of the transpiration fluid 210. In yet another aspect, theburner device 300 may be configured to receive the fuel/fuel mixturefrom the mixing arrangement 250 and to direct a substantially uniformlinear flow of the fuel/fuel mixture into the inlet portion 222A of thecombustion chamber 222, wherein the helical flow of the transpirationfluid 210 is configured to induce swirl of the fuel/fuel mixture and/orthe combustion products within the combustion chamber 222.

Each such arrangement may have a separate purpose and/or effect. Forexample, directing the flow of the fuel/fuel mixture in a directionopposite to the helical flow of the transpiration fluid 210 may slow orstop the induced swirl in the fuel/fuel mixture due to friction betweenthe opposing flows. As such, combustion of the fuel/fuel mixture mayalso be slowed. Conversely, if the fuel/fuel mixture is directed in thesame direction as the helical flow of the transpiration fluid 210,swirling of the fuel/fuel mixture and/or the combustion products may beenhanced, possibly decreasing the time needed for substantially completecombustion of the fuel/fuel mixture or otherwise increasing theproportion of the fuel/fuel mixture combusted during the process (i.e.,increase the burnout ratio of the fuel). Directing the fuel/fuel mixturein a substantially uniform linear flow may be advantageous, forinstance, when the fuel/fuel mixture includes solids or otherparticulates, as previously disclosed, since the flow is unimpeded bymechanical devices, and wherein the desired swirling thereof can then beinduced by the helical flow of the transpiration fluid 210 to enhancecombustion thereof.

Accordingly, such effects can, in some aspects, be combined in order toenhance the efficacy of the combustor apparatus 220. For example, asshown in FIG. 2E, the combustion chamber 222 may include a combustionsection 244A disposed toward the inlet portion 222A and apost-combustion section 244B disposed toward the outlet portion 222B,wherein the transpiration member 230 may be configured such that thehelical flow of the transpiration fluid 210 over the post-combustionsection 244B is opposite to the helical flow of the transpiration 210over the combustion section 244A so as to reverse the induced swirl ofthe combustion product in the post-combustion section 244B with respectto the induced swirl of the fuel/fuel mixture in the combustion section244A. In such instances, the fuel/fuel mixture may be directed intocombustion section 244A of the combustion chamber 222 in the samedirection as the helical flow of the transpiration fluid 210, so as toenhance combustion thereof, as previously discussed. Reversing thedirection of the helical flow of the transpiration fluid 210 in thepost-combustion section 244B may, for instance, effectuate a“counter-swirl” in the combustion products by increasing local shear,and thereby enhancing mixing of the combustion products. In doing so,the combustion products may be more quickly and completely mixed intothe exit flow stream from the outlet portion 222B so as to provide amore homogenous exit flow stream from the combustor apparatus 220.

In further aspects, the transpiration member 230 may be configured suchthat the helical flow of the transpiration fluid 210 is alternatinglyreversed along at least a section thereof so as to alternatingly reversethe induced swirl of the fuel/fuel mixture and/or the combustionproducts between the inlet portion 222A and the outlet portion 222B.Such alternating section of opposing helical flow of the transpirationfluid 210 may, for instance, increase local turbulence and thus increasemixing of the fuel/fuel mixture and/or the combustion products. In someinstances, for example, to further increase such local turbulence toinduce other changes in the combustion dynamics, kinetics, and/or theflow path within or through the combustion chamber 222, thetranspiration member 230 may further include at least one transpirationport 246 (see, e.g., FIG. 2G) extending therethrough, wherein the atleast one transpiration port 246 may be configured to direct asupplemental linear flow of the transpiration fluid 210 into thefuel/fuel mixture and/or the combustion products so as to possiblyaffect flow characteristics thereof, as well as combustion dynamics andkinetics. In some aspects, an appropriately configured jet of thetranspiration fluid directed through the at least onelaterally-extending transpiration port 246 may be sufficient tobifurcate the flow within the combustion chamber 222 or otherwise causethe flow to “bend” around the jet of the transpiration fluid, therebyallowing the flow to be shaped along the length of the combustionchamber 222. Where more than one of such transpiration ports 246 areused, the transpiration ports 246 may be spaced apart, angularly and/orlongitudinally with respect to the combustion chamber 222, so as to, forinstance, move higher temperature combustion regions to other sectorswithin the combustion chamber 222 (i.e., prevent localized heating oroverheating of certain sectors of the combustion chamber 222), or inducemixing between different combustion regions having differenttemperatures.

In some instances, the outer transpiration member 331, the pressurecontainment member 338, the heat transfer jacket 336 and/or theinsulation layer 339 may be configured, either individually or incombination, to provide a “manifold” effect (i.e., to provide asubstantially uniformly distributed supply) with regard to the deliveryof the transpiration substance/fluid 210 to and through the innertranspiration member 332 and into the combustion chamber 222. That is, asubstantially uniform supply (in terms of flow rate, pressure, or anyother suitable and appropriate measure) of the transpiration substance210 into the combustion chamber 222 may be achieved by configuring theouter transpiration member 331, the pressure containment member 338, theheat transfer jacket 336 and/or the insulation layer 339 to provide auniform supply of the transpiration substance 210 to the innertranspiration member 332, or the supply of the transpiration substance210 about the outer surface of the inner transpiration member 332 may beparticularly customized and configured such that a substantially uniformdistribution of the transpiration substance 210 within, about or alongthe combustion chamber 222 is achieved. Such substantially uniformdistribution and supply of the transpiration substance 210 into thecombustion chamber 222 may minimize or prevent the formation of hotcombustion fluid vortices, since such hot combustion fluid vortices mayotherwise be formed through interaction between nonuniform transpirationfluid flow and the combustion fluid flow, and such vortices may, inturn, impinge upon and potentially damage the inner transpiration member332. In some aspects, the uniformity of the distribution of thetranspiration substance 210 within the combustion chamber 222 isdesirable in at least a local manner or frame of reference. That is,over relatively large distances along the combustion chamber 222, theuniformity of the flow of the transpiration substance/fluid 210 mayvary, but it may be desirable and/or necessary for the flow to varysmoothly to prevent discontinuities in the flow profile that may beconducive to forming the potentially-damaging vortices.

The surface of the inner transpiration member 332 is also heated bycombustion products. As such, the porous inner transpiration member 332may be configured to have a suitable thermal conductivity such that thetranspiration fluid 210 passing through the inner transpiration member332 is heated, while the porous inner transpiration member 332 issimultaneously cooled, resulting in the temperature of the surface ofthe inner transpiration member 332 defining the combustion chamber 222being, for example, between about 200° C. and about 700° C. (and, insome instances, up to about 1000° C.) in the region of the highestcombustion temperature. The fluid barrier wall or buffer layer 231formed by the transpiration fluid 210 in cooperation with the innertranspiration member 332 thus buffers interaction between the innertranspiration member 332 and the high temperature combustion productsand the slag or other contaminant particles and, as such, buffers theinner transpiration member 332 from contact, fouling, or other damage.Further, the transpiration fluid 210 introduced into the combustionchamber 222 via the inner transpiration member 332 in such a manner soas to regulate an exit mixture of the transpiration fluid 210 and thecombustion products about the outlet portion 222B of the combustionchamber 222 at a temperature of between about 400° C. and about 3500° C.

One skilled in the art will appreciate that reference to an exit mixtureof the transpiration fluid 210 and the combustion products about theoutlet portion 222B of the combustion chamber 222 at a temperature ofbetween about 400° C. and about 3500° C., does not necessarily indicatethat the temperature of the exit mixture peaks at the exit of the outletportion 222B of the combustion chamber 222. In practice, the combustortemperature will always reach a much higher temperature somewhere alongthe length thereof, between the inlet portion 222A and the outletportion 222B of the combustion chamber 222, as schematicallyillustrated, for example, in FIG. 1A (with a relative temperatureplotted along the y-axis, and a relative position along the combustionchamber, between the inlet portion and outlet portion, plotted along thex-axis). In general, it may be desirable to attain a sufficiently hightemperature in order to complete the combustion process in thecombustion chamber 222 rapidly enough so that the reaction is completebefore the exit mixture exits the combustion chamber 222. After the peaktemperature is attained within the combustion chamber 222, thetemperature of the exit mixture may, in some instances, fall due todilution from the transpiration substance/fluid 210.

According to certain aspects, a transpiration fluid 210 suitable forimplementation in a combustor apparatus 220 as disclosed herein mayinclude any appropriate fluid capable of being provided at a flow ofsufficient quantity and pressure through the inner transpiration member332 to form the fluid barrier wall/buffer layer 231 and capable ofdiluting the combustion products to produce a suitable final outlettemperature of the working fluid/combustion products exit stream. Insome aspects, CO₂ may be a suitable transpiration fluid 210 in that thefluid barrier wall/buffer layer formed thereby may demonstrate goodthermal insulating properties as well as desirable visible light and UVlight absorption properties. If implemented, CO₂ is used as asupercritical fluid. Other examples of a suitable transpiration fluidinclude, for example, H₂O or cooled combustion product gases recycledfrom downstream processes. Some fuels may be used as transpirationfluids during startup of the combustor apparatus to achieve, forexample, appropriate operating temperatures and pressures in thecombustion chamber 222 prior to injection of the fuel source used duringoperation. Some fuels may also be used as the transpiration fluid toadjust or maintain the operating temperatures and pressures of thecombustor apparatus 220 during switchover between fuel sources, such aswhen switching from coal to biomass as the fuel source. In some aspects,two or more transpiration fluids can be used. The transpiration fluid210 can be optimized for the temperature and pressure conditions of thecombustion chamber 222 where the transpiration fluid 210 forms the fluidbarrier wall/buffer layer 231.

Aspects of the present disclosure thus provide apparatuses and methodsfor producing power, such as electrical power, through use of a highefficiency fuel combustor apparatus 220 and an associated working fluid236. The working fluid 236 is introduced to the combustor apparatus 220in conjunction with an appropriate fuel 254 and oxidant 242, and anyassociated materials that may also be useful for efficient combustion.In particular aspects, implementing a combustor apparatus 220 configuredto operate at relatively high temperatures (e.g., in the range ofbetween about 1,300° C. and about 5,000° C.), the working fluid 236 canfacilitate moderation of the temperature of a fluid stream exiting thecombustor apparatus 220 so that the fluid stream can be utilized byextracting energy therefrom for power production purposes.

In certain aspects, a transpiration-cooled combustor apparatus 220 canbe implemented in a power generation system, using a circulated workingfluid 236 comprising, for example, predominantly CO₂ and/or H₂O. In oneparticular aspect, the working fluid 236 entering the combustorapparatus 220 preferably comprises substantially only CO₂. In thecombustor apparatus 220, operating under oxidizing conditions, the CO₂working fluid 236 can comingle with one or more components of the fuel254, an oxidant 242, and any products of the fuel combustion process.Thus, the working fluid 236 directed toward the outlet portion 222B ofand exiting the combustor apparatus 220, which may also be referred toherein as an exit fluid stream, may comprise, as shown in FIG. 1,predominantly CO₂ (in instances where the working fluid is predominantlyCO₂) along with smaller amounts of other materials, such as H₂O, O₂, N₂,argon, SO₂, SO₃, NO, NO₂, HCl, Hg and traces of other components whichmay be products of the combustion process (e.g., particulates orcontaminants, such as ash or liquefied ash). See element 150 in FIG. 1.Operation of the combustor apparatus 220 under reducing conditions mayresult in an exit fluid stream with a different list of possiblecomponents, including CO₂, H₂O, H₂, CO, NH₃, H₂S, COS, HCl, N₂, andargon, as shown in element 175 in FIG. 1. As discussed in further detailherein, the combustion process associated with the combustor apparatus220 may be controlled such that the nature of the exit fluid stream canbe either reducing or oxidizing, wherein either instance can provideparticular benefits.

In particular aspects, the combustor apparatus 220 may be configured asa high efficiency, transpiration-cooled combustor apparatus capable ofproviding relatively complete combustion of a fuel 254 at a relativelyhigh operating temperature, for example, in the range of between about1300° C. and about 5000° C. Such a combustor apparatus 220 may, in someinstances, implement one or more cooling fluids, and/or one or moretranspiration fluids 210. In association with the combustor apparatus220, additional components may also be implemented. For example, an airseparation unit may be provided for separating N₂ and O₂, and a fuelinjector device may be provided for receiving O₂ from the air separationunit and combining the O₂ with CO₂ and/or H₂O, and a fuel streamcomprising a gas, a liquid, a supercritical fluid, or a solidparticulate fuel slurried in a high density CO₂ fluid.

In another aspect, the transpiration-cooled combustor apparatus 220 mayinclude a fuel injector for injecting a pressurized fuel stream into thecombustion chamber 222 of the combustor apparatus 220, wherein the fuelstream may comprise a processed carbonaceous fuel 254, a fluidizingmedium 255 (which may comprise the working fluid 236, as discussedherein), and oxygen 242. The oxygen (enriched) 242 and the CO₂ workingfluid 236 can be combined as a homogeneous supercritical mixture. Thequantity of oxygen present may be sufficient to combust the fuel andproduce combustion products having a desired composition. The combustorapparatus 220 may also include a combustion chamber 222, configured as ahigh pressure, high temperature combustion volume, for receiving thefuel stream, as well as a transpiration fluid 210 entering thecombustion volume through the walls of a porous transpiration member 230defining the combustion chamber 222. The feed rate of the transpirationfluid 210 may be used to control the combustor apparatus outletportion/turbine inlet portion temperature to a desired value and/or tocool the transpiration member 230 to a temperature compatible with thematerial forming the transpiration member 230. The transpiration fluid210 directed through the transpiration member 230 provides afluid/buffer layer at the surface of the transpiration member 230defining the combustion chamber 222, wherein the fluid/buffer layer mayprevent particles of ash or liquid slag resulting from certain fuelcombustion from interacting with the exposed walls of the transpirationmember 230.

Aspects of a high efficiency combustor apparatus may also be configuredto operate with a variety of fuel sources including, for example,various grades and types of coal, wood, oil, fuel oil, natural gas,coal-based fuel gas, tar from tar sands, bitumen, bio-fuel, biomass,algae, and graded combustible solid waste refuse. Particularly, a coalpowder or particulate solid can be used. Though an exemplary coalburning combustor apparatus 220 is disclosed herein, one skilled in theart will appreciate that the fuel used in the combustor apparatus 220 isnot limited to a specific grade of coal. Moreover, because of the highpressures and high temperatures maintained by the oxygen-fueledcombustor apparatus disclosed herein, a wide variety of fuel types maybe implemented, including coal, bitumen (including bitumen derived fromtar sands), tar, asphalt, used tires, fuel oil, diesel, gasoline, jetfuel (JP-5, JP-4), natural gas, gases derived from the gasification orpyrolysis of hydro-carbonaceous material, ethanol, solid and liquidbiofuels, biomass, algae, and processed solid refuse or waste. All suchfuels are suitably processed to allow for injection into the combustionchamber 222 at sufficient rates and at pressures above the pressurewithin the combustion chamber 222. Such fuels may be in liquid, slurry,gel, or paste form with appropriate fluidity and viscosity at ambienttemperatures or at elevated temperatures (e.g., between about 38° C. andabout 425° C.). Any solid fuel materials are ground or shredded orotherwise processed to reduce particles sizes, as appropriate. Afluidization or slurrying medium can be added, as necessary, to achievea suitable form and to meet flow requirements for high pressure pumping.Of course, a fluidization medium may not be needed depending upon theform of the fuel (i.e., liquid or gas). Likewise, the circulated workingfluid may be used as the fluidization medium, in some aspects.

In some aspects, the combustion chamber 222 is configured to sustain acombustion temperature of between about 1,300° C. and about 5,000° C.The combustion chamber 222 may further be configured such that the fuelstream (and the working fluid 236) can be injected or otherwiseintroduced into the combustion chamber 222 at a pressure greater thanthe pressure at which combustion occurs. Where a coal particulate is thecarbonaceous fuel, the coal particles can be slurried in a supercriticalCO₂ fluid or water, formed by mixing liquid CO₂ or water with the groundsolid fuel to form a pumpable slurry. In such instances, the liquid CO₂can have a density, for example, in the range of between about 450 kg/m³and about 1100 kg/m³ and the mass fraction of solid fuel can be in therange of between about 25% and about 95% (e.g., between about 25 weight% and about 55 weight %). Optionally, a quantity of O₂ can be mixed withthe coal/CO₂ slurry sufficient to combust the coal to produce a desiredcomposition of the combustion products. Optionally, the O₂ can beseparately injected into the combustion chamber 222. The combustorapparatus 220 may include a pressure containment member 338 at leastpartially surrounding the transpiration member 230 defining thecombustion chamber 230, wherein an insulating member 339 can be disposedbetween the pressure containment member 338 and the transpiration member230. In some instances, a heat removal device 350, such as a jacketedwater cooling system defining water-circulating jackets 337, may beengaged with the pressure containment member 338 (i.e., externally tothe pressure containment member 338 forming the “shell” of the combustorapparatus 220). The transpiration fluid 210 implemented in connectionwith the transpiration member 230 of the combustor apparatus 220 can be,for example, CO₂ mixed with minor quantities of H₂O and/or an inert gas,such as N₂ or argon. The transpiration member 230 may comprise, forexample, a porous metal, a ceramic, a composite matrix, a layeredmanifold, any other suitable structure, or combinations thereof. In someaspects, the combustion within the combustion chamber 222 can produce ahigh pressure, high temperature exit fluid stream, which may besubsequently directed to a power-producing apparatus, such as a turbine,for expansion in relation thereto.

With respect to the apparatus aspects illustrated in FIG. 1, thecombustor apparatus 220 may be configured to receive the oxygen 242 at apressure of about 355 bar. Further, the particulate solid fuel (e.g.,powdered coal) 254, and the fluidization fluid (e.g., liquid CO₂) 255may also be received at a pressure of about 355 bar. Likewise, theworking fluid (e.g., heated, high pressure, possibly recycled, CO₂fluid) 236 may be provided at a pressure of about 355 bar, and atemperature of about 835° C. According to aspects of the presentdisclosure, however, the fuel mixture (fuel, fluidization fluid, oxygen,and working fluid) may be received in the inlet portion 222A of thecombustion chamber 222 at a pressure of between about 40 bar and about500 bar. The relatively high pressures implemented by aspects of thecombustor apparatus 220, as disclosed herein, may function toconcentrate the energy produced thereby to a relatively high intensityin a minimal volume, essentially resulting in a relatively high energydensity. The relatively high energy density allows downstream processingof this energy to be performed in a more efficient manner than at lowerpressures, and thus provides a viability factor for the technology.

Aspects of the present disclosure may thus provide an energy density atorders of magnitude greater than existing power plants (i.e., by 10-100fold). The higher energy density increases the efficiency of theprocess, but also reduces the cost of the equipment needed to implementthe energy transformation from thermal energy to electricity, byreducing the size and mass of the equipment, thus the cost of theequipment.

When implemented, the CO₂ fluidization fluid 255, which is a liquid atany pressure between the CO₂ triple point pressure and the CO₂ criticalpressure, is mixed with the powdered coal fuel 254 to form a mixture inthe proportion of about 55% CO₂ and about 45% powdered coal by mass orother mass fraction, such that the resulting slurry can be pumped by asuitable pump (as a fluid slurry) to the combustion chamber 222 at thenoted pressure of about 355 bar. In some aspects, the CO₂ and powderedcoal may be mixed, prior to pumping, at a pressure of about 13 bar. TheO₂ stream 242 is mixed with the recycle CO₂ working fluid stream 236 andthat combination then mixed with the powdered coal/CO₂ slurry to form asingle fluid mixture. The proportion of O₂ to coal may be selected to besufficient to completely combust the coal with an additional 1% ofexcess O₂. In another aspect, the quantity of O₂ can be selected so asto allow a portion of the coal to be substantially completely oxidized,while another portion is only partially oxidized, resulting in a fluidmixture which is reducing and which includes some H₂+CO+CH₄. In such amanner, a two stage expansion of the combustion products may beimplemented, as necessary or desired, with some O₂ injection andreheating between the first and second stages. Further, since the fuel(coal) is only partially oxidized in the first stage (i.e., a firstcombustion chamber at a temperature of between about 400° C. and about1000° C.), any incombustible elements in the carbonaceous fuel exitingthe first stage are formed as solid particulates within the combustionproducts. Upon filtration of the solid particulates, for example, byvortex and/or candle filters, the carbonaceous fuel may then besubstantially completely oxidized in second stage (i.e., a secondcombustion chamber) so as to produce a final combustion producttemperature of between about 1300° C. and about 3500° C.

In further aspects, the quantity of CO₂ present in the combustionchamber 222 via the fuel mixture is selected to be sufficient to achievea combustion temperature (adiabatic or otherwise) of about 2400° C.,though the combustion temperature can be in the range of between about1300° C. and about 5000° C. The fuel mixture of O₂+coal slurry+heatedrecycle CO₂ is provided, in one aspect, at a resultant temperature belowthe auto-ignition temperature of that fuel mixture. In order to achievethe indicated conditions, the solid carbonaceous fuel (e.g., coal) ispreferably provided at an average particle size of between about 50microns and about 200 microns, for example, by grinding the solid coalin a coal mill. Such a grinding process may be performed in a millconfigured to provide a minimal mass fraction of particles below about50 microns. In this manner, any incombustible elements therein that areliquefied to form the liquid slag droplets in the combustion process maybe greater than about 10 microns in diameter. In some aspects, the fuelmixture comprising the CO₂+O₂+powdered coal slurry, at a temperature ofabout 400° C., may be directed into the combustion chamber 222 at apressure of about 355 bar, wherein the net pressure at combustion withinthe combustion chamber 222 may be about 354 bar. The temperature withinthe combustion chamber 222 can range from between about 1300° C. andabout 5000° C., and in some preferred aspects, only a single combustionstage is implemented.

In one example of a combustor apparatus 220, as disclosed herein, a 500MW net electrical power system may be configured to operate with CH₄fuel at an efficiency (lower heating value basis) of about 58%, at thefollowing conditions:

Combustion pressure: 350 atm

Fuel input: 862 MW

Fuel flow: 17.2 kg/second

Oxygen flow: 69.5 kg/second

The CH₄ and O₂ are mixed with 155 kg/second of CO₂ working fluid andcombusted to produce a exit fluid stream comprising CO₂, H₂O and someexcess O₂ at an adiabatic temperature of 2400° C. The combustion chambermay have an internal diameter of about 1 m and a length of about 5 m. Aflow of 395 kg/second of CO₂ at a temperature of about 600° C. isdirected toward the transpiration member, which may be about 2.5 cmthick, and is directed through the transpiration member. This CO₂ isheated convectively from heat conducted through the transpiration memberwhich originates from radiation of the combustion within the combustionchamber to the transpiration member.

About the inner surface thereof defining the combustion chamber, thetranspiration member surface temperature may be about 1000° C., whilethe exit fluid stream of 636.7 kg/second may be at a temperature ofabout 1350° C. In such instances, the average residence time forcombustion and dilution of the combustion products is about 1.25seconds. Further, the average radially inward velocity for thetranspiration fluid entering the combustion chamber through thetranspiration member is approximately 0.15 m/s.

Amending the example for a coal-fueled combustor apparatus results in aconfiguration with an average residence time for combustion and dilutionof the combustion products in the combustion chamber of about 2.0seconds, and a combustion chamber length of about 8 m, with an internaldiameter of about 1 m. The net efficiency of the system with CO₂ as thedilution (transpiration) fluid is thus about 54% (lower heating valuebasis). In such instances, the transpiration fluid radially inwardvelocity may be about 0.07 m/s. Under such conditions, FIG. 5 shows aschematic trajectory of a 50 micron diameter liquid slag particleprojected radially outward at about 50 m/s toward the transpirationmember from a distance of 1 mm therefrom. As illustrated, the particlewould reach a minimum 0.19 mm from the transpiration member before beingcarried back into the exit fluid flow stream by the transpiration fluidflow through the transpiration member. In such instances, thetranspiration fluid flow through the transpiration member effectivelybuffers interaction between the transpiration member and liquid slagparticles resulting from the combustion process.

Aspects of the disclosed combustor apparatus may be implemented insuitable power production systems using associated methods, as will beappreciated by one skilled in the art. For example, such a powerproduction system may comprise one or more injectors for providing fuel(and optionally a fluidizing medium), an oxidant, and a CO₂ workingfluid; a transpiration-cooled combustor apparatus, as disclosed herein,having at least one combustion stage for combusting the fuel mixture,and provides an exit fluid stream. A transformation apparatus (see,e.g., element 500 in FIG. 6) may be configured to receive the exit fluidstream (combustion products and working fluid), and to be responsive tothe exit fluid stream to transform energy associated therewith intokinetic energy, wherein the transformation apparatus may be, forexample, a power production turbine having an inlet and an outlet andwherein power is produced as the exit fluid stream expands. Moreparticularly, the turbine may be configured to maintain the exit fluidstream at a desired pressure ratio between the inlet and the outlet. Agenerator device (see, e.g., element 550 in FIG. 6) may also be providedto transform the kinetic energy of the turbine into electricity. Thatis, the exit fluid stream may be expanded from a high pressure to alower pressure to produce shaft power which can then be converted toelectric power. A heat exchanger may be provided for cooling the exitfluid stream from the turbine outlet and for heating the CO₂ workingfluid entering the combustor apparatus. One or more devices may also beprovided for separating the exit fluid stream leaving the heat exchangerinto pure CO₂ and one or more further components for recovery ordisposal. Such a system may also comprise one or more devices forcompressing the purified CO₂ and for delivering at least a portion ofthe CO₂ separated from the exit fluid stream into a pressurizedpipeline, while the remaining portion is recycled as the working fluidwhich is heated by the heat exchanger. One skilled in the art, however,will appreciate that, though the present disclosure involves directimplementation of the exit fluid stream, in some instances, therelatively high temperature exit fluid stream may be implementedindirectly. That is, the exit fluid stream may be directed to a heatexchanger, wherein the thermal energy associated therewith is used toheat a second working fluid stream, and the heated second fluid workingstream then directed to a transformation device (e.g., a turbine) togenerate power. Further, one skilled in the art will appreciate thatmany other such arrangements may be within the scope of the presentdisclosure.

In particular aspects of the disclosure, the composition of thecarbonaceous fuel is such that incombustible elements (i.e.,contaminants) may be included therein, and remain present in thecombustion products/exit fluid stream following the combustion process.Such may be the case where the carbonaceous fuel is a solid such ascoal. In those aspects, direct implementation of the exit fluid streammay result in build-up of such incombustible elements on or other damageto the subsequent transformation apparatus (turbine) if the exit fluidstream is channeled directly thereto. One skilled in the art will alsoappreciate that such incombustible elements may not necessarily bepresent when implementing other forms of carbonaceous fuel such as aliquid or gas (i.e., natural gas). Accordingly, in aspects implementinga solid carbonaceous fuel source and a direct interaction between theexit fluid stream and the transformation apparatus, the power system(combustor apparatus and transformation apparatus) may further include aseparator apparatus disposed between the combustor apparatus and thetransformation apparatus. In such instances, the separator apparatus maybe configured to substantially remove liquefied incombustible elementsfrom the combustion products/exit fluid stream received thereby, priorto the combustion products/exit fluid stream being directed to thetransformation apparatus. Further, in aspects implementing a separatorapparatus, the disclosed transpiration substance may be introduced bothupstream and downstream of the separator apparatus. More particularly,the transpiration substance may be first introduced into the combustionchamber, via the transpiration member and upstream of the separatorapparatus, so as to regulate a mixture of the transpiration substanceand the combustion products entering the separator apparatus above aliquification temperature of the incombustible elements. Subsequent tothe separator apparatus, a transpiration substance delivery device (see,e.g., element 475 in FIG. 6) may be configured to deliver thetranspiration substance to the combustion products exiting the separatorapparatus, and having the liquefied incombustible elements substantiallyremoved therefrom, so as to regulate a mixture of the transpirationsubstance and the combustion products entering the transformationapparatus at a temperature of between about 400° C. and about 3500° C.

As previously discussed, aspects of the combustor apparatus may includethe capability of achieving a combustion temperature which causes theincombustible elements in the solid carbonaceous fuel to be liquefiedduring the combustion process. In such instances, provisions forremoving the liquefied incombustible elements may be applied such as,for example, a separator apparatus 340 such as a cyclonic separator, asshown in FIG. 4. Generally, aspects of such a cyclonic separatorimplemented by the present disclosure may comprise a plurality ofserially-arranged centrifugal separator devices 100, including an inletcentrifugal separator device 100A configured to receive the combustionproducts/exit fluid stream and the liquefied incombustible elementsassociated therewith, and an outlet centrifugal separator device 100Bconfigured to exhaust the combustion products/exit fluid stream havingthe liquefied incombustible elements substantially removed therefrom.Each centrifugal separator device 100 includes a plurality ofcentrifugal separator elements or cyclones 1 operably arranged inparallel about a central collector pipe 2, wherein each centrifugalseparation element/cyclone 2 is configured to remove at least a portionof the liquefied incombustible elements from the combustionproducts/exit fluid stream, and to direct the removed portion of theliquefied incombustible elements to a sump 20. Such a separatorapparatus 340 may be configured to operate at an elevated pressure and,as such, may further comprise a pressure-containing housing 125configured to house the centrifugal separator devices and the sump.According to such aspects, the pressure-containing housing 125 may be anextension of the pressure containment member 338 also surrounding thecombustor apparatus 220, or the pressure-containing housing 125 may be aseparate member capable of engaging the pressure containment member 338associated with the combustor apparatus 220. In either instance, due tothe elevated temperature experienced by the separator apparatus 340 viathe exit fluid stream, the pressure-containing housing 125 may alsoinclude a heat-dispersion system, such as a heat transfer jacket havinga liquid circulated therein (not shown), operably engaged therewith forremoving heat therefrom. In some aspects, a heat recovery device (notshown) may be operably engaged with the heat transfer jacket, whereinthe heat recovery device may be configured to receive the liquidcirculated in the heat transfer jacket and to recover thermal energyfrom that liquid.

More particularly, the (slag removal) separator apparatus 340, shown inFIG. 4, is configured to be serially disposed with the combustorapparatus 220 about the outlet portion 222B thereof for receiving theexit fluid stream/combustion products therefrom. Thetranspiration-cooled exit fluid stream from the combustor apparatus 220,with the liquid slag (incombustible elements) droplets therein, isdirected to enter a central collector provision 2A of the inletcentrifugal separator device 100A via a conical reducer 10. In oneaspect, the separator apparatus 340 may include three centrifugalseparator devices 100A, 100B, 100C (though one skilled in the art willappreciate that such a separator apparatus may include one, two, three,or more centrifugal separator devices, as necessary or desired). In thisinstance, the three centrifugal separator devices 100A, 100B, 100Coperably arranged in series provides a 3 stage cyclonic separation unit.Each centrifugal separator device includes, for example, a plurality ofcentrifugal separator elements (cyclones 1) arranged about thecircumference of the corresponding central collector pipe 2. The centralcollector provisions 2A and the central collector pipes 2 of the inletcentrifugal separator device 100A, and the medial centrifugal separatordevice 100C are each sealed at the outlet end thereof. In thoseinstances, the exit fluid stream is directed into branch channels 11corresponding to each of the centrifugal separator elements (cyclones 1)of the respective centrifugal separator device 100. The branch channels11 are configured to engage the inlet end of the respective cyclone 1 toform a tangential inlet therefor (which causes, for instance, the exitfluid stream entering the cyclone 1 to interact with the wall of thecyclone 1 in a spiral flow). The outlet channel 3 from each cyclone 1 isthen routed into the inlet portion of the central collector pipe 2 ofthe respective centrifugal separator device 100. At the outletcentrifugal separator device 100B, the exit fluid stream (having theincombustible elements substantially separated therefrom) is directedfrom the central collector pipe of the outlet centrifugal separatordevice 100B and via a collector pipe 12 and an outlet nozzle 5, suchthat the “clean” exit fluid stream can then be directed to a subsequentprocess, such as that associated with the transformation apparatus. Theexemplary three stage cyclonic separation arrangement thus allowsremoval of slag down to, for example, below 5 ppm by mass in the exitfluid stream.

At each stage of the separator apparatus 340, the separated liquid slagis directed from each of the cyclones 1 via outlet tubes 4 which extendtoward a sump 20. The separated liquid slag is then directed into anoutlet nozzle or pipe 14 extending from the sump 20 and thepressure-containing housing 125 for removal and/or recovery ofcomponents therefrom. In accomplishing the removal of the slag, theliquid slag may be directed though a water-cooled section 6 or otherwisethrough a section having a high pressure, cold water connection, whereininteraction with the water causes the liquid slag to solidify and/orgranulate. The mixture of solidified slag and water may then beseparated in a vessel (collection provision) 7 into a slag/water fluidmixture which can be removed through a suitable valve 9, while anyresidual gas may be removed via a separate line 8.

Since the separator apparatus 340 is implemented in conjunction with therelatively high temperature exit fluid stream (i.e., at a temperaturesufficient to maintain the incombustible elements in liquid form with arelatively low viscosity), it may be desirable, in some instances, thatsurfaces of the separator apparatus 340 exposed to one of the combustionproducts/exit fluid stream and the liquefied incombustible elementsassociated therewith be comprised of a material configured to have atleast one of a high temperature resistance, a high corrosion resistance,and a low thermal conductivity. Examples of such materials may includezirconium oxide and aluminum oxide, though such examples are notintended to be limiting in any manner. As such, in certain aspects, theseparator apparatus 340 is configured to substantially remove theliquefied incombustible elements from the combustion products/exit fluidstream and to maintain the incombustible elements in a low viscosityliquid form at least until removal thereof from the sump 20.

As such, as disclosed herein, the slag separation in instances of asolid carbonaceous fuel may be accomplished in a single unit (separatorapparatus 340) which may, in some instances, be readily extracted fromthe system for maintenance and inspection. However, such an aspect mayprovide further advantages, as shown in FIG. 6, whereby the system maybe readily configured to implement a “flex fuel” approach in operationwith respect to the availability of a particular fuel source. Forexample, the single unit separator apparatus 340 may be installed in thesystem, between the combustor apparatus 220 and the transformationapparatus (turbine) 500, when the combustor apparatus 220 used a solidcarbonaceous fuel as the fuel source. Should it be desirable to changeto a liquid or gas carbonaceous fuel source, the separator unit 340 maybe removed from the system (i.e., may not be necessary, as previouslydiscussed) such that the exit fluid stream from the combustor apparatus220 can be directed directly to the transformation apparatus 500. Thesystem may thus also be readily changed back to implement the separatorunit 340 should the fuel availability later dictate a solid carbonaceousfuel source.

Many modifications and other aspects of the disclosure set forth hereinwill come to mind to one skilled in the art to which this disclosurepertains having the benefit of the teachings presented in the foregoingdescriptions and the associated drawings. For example, in some aspects,only a portion of the total flow of the transpiration substance/fluid210 to and through the inner transpiration member 332 and into thecombustion chamber 222, may be necessary to provide the helical flow ofthe transpiration fluid within the combustion chamber 222. In oneinstance, for example, up to about 90% of the total mass flow oftranspiration fluid 210 entering the combustion chamber 222 may beimplemented to provide or induce the helical flow, while maintainingsufficient radial flow of the transpiration fluid 210 into thecombustion chamber 222 to prevent solid or liquid particles orcontaminants from impinging upon the walls of the inner transpirationmember 332 defining the combustion chamber 222.

Further, in some aspects, the combustor apparatus 220 may be configuredand arranged as a partial oxidation device, for example, using the solidfuel (i.e., coal) slurry. In such instances, the partial oxidationcombustor apparatus 220 may be configured to have an operatingtemperature, for example, up to about 1600° C. or, in other instances,in the range of between about 1400° C. and about 1500° C., whereincarbon burnout in the fuel should be below about 2% and, preferably,below 1%. In these instances, the relatively lower operating temperaturefacilitates production of H₂ and CO by minimizing combustion thereof,while facilitating a relatively high carbon conversion rate and usableheat.

In other aspects, the combustor apparatus 220 may be configured tooperate at a relatively high exit temperature of about 5000° C. or more,which may be associated, for example, with an adiabatic flametemperature or other temperature sufficient to facilitate dissociationof the product gases. For example, CO₂ dissociates significantly aboveabout 1600° C.

In yet other aspects, the burner device 300 may be configured andarranged such that there is no premixing of the carbonaceous fuel andthe diffusing CO₂ component upstream thereof. In addition, O₂ may alsobe introduced at the burner tip, for instance through a separate set ofnozzles or with a concentric annular ring surrounding the injectionnozzle(s). In such instances, a diffusion flame may be achievable forcarbonaceous fuels with a high H₂ content. To achieve very hightemperatures at the burner device 300, preheating of the fuel, oxygen,and/or any diluents may also be required.

Therefore, it is to be understood that the disclosure is not to belimited to the specific aspects disclosed and that modifications andother aspects are intended to be included within the scope of theappended claims. Although specific terms are employed herein, they areused in a generic and descriptive sense only and not for purposes oflimitation.

That which is claimed:
 1. An apparatus, comprising: a mixing arrangementconfigured to mix a carbonaceous fuel with enriched oxygen and a workingfluid to form a fuel mixture; and a combustor arrangement defining acombustion chamber having an inlet portion longitudinally spaced apartfrom an opposing outlet portion, the inlet portion being configured toreceive the fuel mixture for combustion within the combustion chamber ata combustion temperature to form a combustion product, the combustionchamber being further configured to direct the combustion productlongitudinally toward the outlet portion, the combustor arrangementcomprising: a pressure containment member; a porous perimetrictranspiration member at least partially defining the combustion chamber,and being at least partially surrounded by the pressure containmentmember, the porous transpiration member being configured to direct atranspiration substance therethrough toward and into the combustionchamber, substantially uniformly about the perimeter thereof, such thatthe transpiration substance is directed substantially tangential to theperimeter of the porous transpiration member, and to flow helicallyabout the perimeter thereof and longitudinally between the inlet portionand the outlet portion, to buffer interaction between the combustionproduct and the porous transpiration member; and a burner deviceconfigured to receive the fuel mixture from the mixing arrangement andto direct the fuel mixture into the inlet portion of the combustionchamber in a direction opposite to the helical flow of the transpirationsubstance, wherein the working fluid and the transpiration substancecomprise supercritical carbon dioxide.
 2. An apparatus according toclaim 1, wherein the mixing arrangement is further configured to mix oneof a solid carbonaceous fuel, a liquid carbonaceous fuel, and a gaseouscarbonaceous fuel with the enriched oxygen, comprising oxygen having amolar purity of greater than about 85%, and the working fluid.
 3. Anapparatus according to claim 1, wherein the carbonaceous fuel is aparticulate solid having an average particle size of between about 50microns and about 200 microns, and the mixing arrangement is furtherconfigured to mix the particulate solid carbonaceous fuel with afluidizing substance, the fluidizing substance comprising one of waterand liquid CO₂ having a density of between about 450 kg/m³ and about1100 kg/m³, the fluidizing substance cooperating with the particulatesolid carbonaceous fuel to form a slurry having between about 25 weight% and about 95 weight % of the particulate solid carbonaceous fuel. 4.An apparatus according to claim 1, wherein the combustion chamber isfurther configured to receive the fuel mixture in the inlet portionthereof at a pressure of between about 40 bar and about 500 bar.
 5. Anapparatus according to claim 1, wherein the combustion temperature isbetween about 1300° C. and about 5000° C., and is configured such thatincombustible contaminants in the carbonaceous fuel are liquefied withinthe combustion product.
 6. An apparatus according to claim 1, whereinthe transpiration substance is configured to be introduced into thecombustion chamber via the porous transpiration member so as to regulatean exit mixture of the transpiration substance and the combustionproduct about the outlet portion of the combustion chamber at atemperature of between about 400° C. and about 3500° C.
 7. An apparatusaccording to claim 6, wherein the transpiration substance is directedthrough the porous transpiration member such that the transpirationsubstance forms a buffer layer immediately adjacent to the poroustranspiration member within the combustion chamber, the buffer layerbeing configured to buffer interaction between the porous transpirationmember and liquefied incombustible contaminants and heat associated withthe combustion product.
 8. An apparatus according to claim 1, whereinthe porous transpiration member is configured to impart a Coanda effecton the transpiration substance directed therethrough and into thecombustion chamber, so as to direct the transpiration substance to flowsubstantially tangential to the perimeter of the porous transpirationmember.
 9. An apparatus according to claim 1, wherein the poroustranspiration member further includes at least one transpiration portextending therethrough, the at least one transpiration port beingconfigured to direct a supplemental linear flow of the transpirationsubstance into one of the fuel mixture and the combustion product so asto affect flow characteristics thereof.
 10. An apparatus according toclaim 1, further comprising a heat removal device associated with thepressure containment member and configured to control a temperaturethereof, the heat removal device comprising a heat transfer jackethaving a liquid circulated therein.
 11. An apparatus according to claim1, wherein the porous transpiration member is further configured todefine pores, the porous transpiration member further having acumulative pore area substantially equal to a surface area of the poroustranspiration member defining the pores.
 12. An apparatus according toclaim 11, wherein the pores are spaced apart and substantially uniformlydistributed about the porous transpiration member and between the inletand outlet portions thereof.
 13. An apparatus according to claim 1,further comprising a transformation apparatus configured to receive thecombustion product from the outlet portion of the combustion chamber,the transformation apparatus being responsive to the combustion productto transform energy associated therewith into kinetic energy.
 14. Anapparatus according to claim 13, wherein the carbonaceous fuel is asolid, and the apparatus further comprises a separator apparatusdisposed between the combustor arrangement and the transformationapparatus, the separator apparatus being configured to substantiallyremove liquefied incombustible contaminants from the combustion productreceived thereby prior to the combustion product being directed to thetransformation apparatus.
 15. An apparatus according to claim 14,wherein the transpiration substance is configured to be introduced intothe combustion chamber via the porous transpiration member so as toregulate a mixture of the transpiration substance and the combustionproduct entering the separator apparatus above a liquificationtemperature of the incombustible contaminants.
 16. An apparatusaccording to claim 15, further comprising a transpiration substancedelivery device disposed subsequently to the separator apparatus andconfigured to deliver the transpiration substance to the combustionproduct having the liquefied incombustible contaminants substantiallyremoved therefrom so as to regulate a mixture of the transpirationsubstance and the combustion product entering the transformationapparatus at a temperature of between about 400° C. and about 3500° C.17. An apparatus according to claim 14, wherein the separator apparatusfurther comprises a plurality of serially arranged centrifugal separatordevices, each centrifugal separator device having a plurality ofcentrifugal separator elements operably arranged in parallel, andwherein the liquefied incombustible contaminants removed from thecombustion product by the separator apparatus are removably collected ina sump associated with the separator apparatus.
 18. An apparatusaccording to claim 13, wherein the transformation apparatus comprisesone of a turbine device configured to be responsive to the combustionproduct so as to transform the energy associated therewith into kineticenergy, and a generator device configured to transform the kineticenergy into electricity.
 19. An apparatus according to claim 1, whereinthe transpiration substance is also supplied to the mixing arrangementas the working fluid.
 20. An apparatus according to claim 1, furthercomprising at least one transpiration substance source configured tosupply the transpiration substance to at least one of the mixingarrangement as the working fluid and the transpiration member as thetranspiration substance.
 21. An apparatus, comprising: a mixingarrangement configured to mix a carbonaceous fuel with enriched oxygenand a working fluid to form a fuel mixture; and a combustor arrangementdefining a combustion chamber having an inlet portion longitudinallyspaced apart from an opposing outlet portion, the inlet portion beingconfigured to receive the fuel mixture for combustion within thecombustion chamber at a combustion temperature to form a combustionproduct, the combustion chamber being further configured to direct thecombustion product longitudinally toward the outlet portion, thecombustor arrangement comprising: a pressure containment member; aporous perimetric transpiration member at least partially defining thecombustion chamber, and being at least partially surrounded by thepressure containment member, the porous transpiration member beingconfigured to direct a transpiration substance therethrough toward andinto the combustion chamber, substantially uniformly about the perimeterthereof, such that the transpiration substance is directed substantiallytangential to the perimeter of the porous transpiration member, and toflow helically about the perimeter thereof and longitudinally betweenthe inlet portion and the outlet portion, to buffer interaction betweenthe combustion product and the porous transpiration member; and a burnerdevice configured to receive the fuel mixture from the mixingarrangement and to direct a substantially uniform linear flow of thefuel mixture into the inlet portion of the combustion chamber, whereinthe helical flow of the transpiration substance is configured to induceswirl of the fuel mixture within the combustion chamber.
 22. Anapparatus according to claim 21, wherein the combustion chamber includesa combustion section disposed toward the inlet portion and apost-combustion section disposed toward the outlet portion, and whereinthe porous transpiration member is configured such that the helical flowof the transpiration substance over the post-combustion section isopposite to the helical flow of the transpiration substance over thecombustion section so as to reverse the induced swirl of the combustionproduct in the post-combustion section with respect to the induced swirlof the fuel mixture in the combustion section.
 23. An apparatusaccording to claim 21, wherein the porous transpiration member isconfigured such that the helical flow of the transpiration substance isalternatingly reversed along at least a section thereof so as toalternatingly reverse the induced swirl of one of the fuel mixture andthe combustion product between the inlet portion and the outlet portion.